Method of making a control mechanism



Dec. 25, 1962 J. H. swATs ETAL 3,

METHOD OF MAKING A CONTROL MECHANISM Original Filed Oct. 21, 1957 9 Sheets-Sheet l INVENTORS JOHN H. awA'rs BYSIDNEY E- HAGERTY.

ATTORNEY Dec. 25, 1962 J. H. swATs ETAL METHOD OF MAKING A CONTROL MECHANISM- Original Filed Oct. 21, 1967 9 Sheets-Sheet 2 INVENTORS JOHN H. SWARS BY SIDNEY E. HAG'ERTI', 22% fi. W

A TTOR/VE'Y Dec. 25, 1962 J, swA s ETAL 3,069,764

METHOD OF MAKING A CONTROL MECHANISM Original Filed 001;. 21, 1957 9 Sheets-Sheet 5 72 U W W ATTORNEY 1 INVENTORS Ma I JOHN H, SWAT'G v L BY SIDNEX mam" Dec. 25, 1962 J. H. SWATS ETAL METHOD OF MAKING A CONTROL MECHANISM Original Filed Oct. 21, 1957 9 Sheets-Sheet 4 INVENTORS JOHN H- QWA 76 BYS/DNEY E. HAGERTY Dec. 25, 1962 J, sw s ETAL 3,069,764

METHOD OF MAKING A CONTROL MECHANISM Original Filed Oct. 21. 1957 9 Sheets-Sheet 5 I ENTORS Jomv H. ywors Eva/am E. mean ATTORNEY Dec. 25, 1962 J. H. SWATS ETAL METHOD OF MAKING A CONTROL MECHANISM Original Filed Oct. 21, 1957 9 Sheets-5heet 6 m m Wm M E M Dec. 25, 1962 J. H. SWATS ETAL 3,069,764

METHOD OF MAKING A CONTROL MECHANISM Original Filed 001:. 21, 1957 9 Sheets-Sheet 7 Jon/v H. W5? e/nun 2 HMERTY Arron/vex Dec. 25, 1962 4.1-1. SWATS ETAL 3, ,7 4

METHOD OF MAKING A CONTROL MECHANISM Original Filed Oct. 21, 1957 9 Sheets-Sheet 8 1 ENTORS Jamv H. ymrs yS/DNEY "465R" ATTORNEY Dec. 25, 1962 J. H. swATs ETAL METHOD OF MAKING A CONTROL MECHANISM Ofiginal Filed Oct. 21, 1957 9 Sheets-Sheet 9 CABLE LOAD 83.

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ayslolvtr E. #065877 ATTOR/VE Y 4- C sis. (Cl. as ins This invention relates to a control mechanism and particularly to the operating portion of a parking brake mechanism which is actuated by ioot applied effort. This application is a division or US. application Serial No. 691,390, filed October 21, 1957, now abandoned.

it is usually the practice in vehicle brake systems to provide both service and auxiliary brake applying systems, the latter being used for parking and also in the event faiiure of the service brake applying system. The auxiliary brake applying system may be associated with a brake which is separate from the service brakes, or it may be associated with the service brakes. The present invention is adapted for both arrangements.

While most of the parking brake systems are actuate by hand, it is generally recognized that greater input effort can be developed by using a foot-operated actuating mechanism. The reason for this is that greater input effort can be developed by pressing downwardly on a pedal with the foot than by a backward yank or drawing effort applied manually to an actuating lever.

With some of the foot actuated parking brake systems, there is required a releasing etort which is proportional to the applying etiort. While it is desirable that parkbrake systems have an operating mechanism by which it is easy to develop a maximum amount of applying effort, it is obvious that this input eiiort should not necessirate releasing forces which are impracticably high. if the release effort is proportional to the input efiort, it is quite possible that the operator cannot develop enough force to release the brakes once they are applied. This would be especially true if the releasing mechanism were hand-operated the applying mechanism foot-operated.

Accordingly, it is an object of this invention to provide a parking brake mechanism in which the effort required to release the brake is constant irrespective of the input effort, thereby enabling construction of a satisfactory foot-ope ted, handreleased parking brake operation.

Another object of the invention from a performance standpoint is that the parking brake operating lever can be moved to any position between two established stops and locked in a preferred position so that any desired applying effort can be maintained on the parking brake, this applying efiort maintainable by a locking mechanism associated with the applying mechanism.

From a construction standpoint, it is an object of the invention to provide a simple operating mechanism which is made from minimum number of parts, most of these parts being constructed by stamping operations.

it forms an important part of the present invention from a construction standpoint that there is provided a depending foot-operated lever, and an associated transverse drum, this drum being eta-movable with the applying lever. A locking mechanism, consisting of a circularly wound spring, is provided in con unction with the drum and has a one-way gripping function with respect to the drum so that the drum is permitted to turn in one direction and may thereafter be locked in any selected angular position by the spring member which prevents turning of the drum in an opposite direction. A further construction feature of the invention is a release mechanism adapted to expand a portion of the spring, this expansion serving to release the gripping effect of the spring on the drum, and thereafter permit return of the drum and release of the parking brake. This expansion of the spring can be accomplished either by manual, pedal, or other mechan- "cal means.

By means or" this simple arrangement of parts which are reduced in number insofar as possible, there results an economical but functionally satisfactory applying mechanism.

Another object of this invention is to provide a novel means for securing one free end portion of the circular spring member to a fixed support.

It is a further object of this invention to provide a novel method of making the parking brake applying mechanism.

Other objects and features of the invention will become apparent from a consideration or the following description, which proceeds with reference to the accompanying drawings, wherein:

FIGURE 1 is an isometric view of a foot-operated parking brake applying mechanism, constituting one embodiment of the invention;

FIGURE 2 is another isometric view of the same embodiment;

FIGURE 3 is a side view of another embodiment of the invention, in which both the applying and releasing mechanisms are pedahoperated;

FIGURE 4 is a front view of the operating mechanism, looking in the direction indicated by the arrows i-=i in FIGURE 3;

FIGURE 5 is a side elevation of a further embodiment of the invention, in which the applying mechanism is pedal-operated and manually released;

FIGURE 6 is a top view of the applying mechanism shown in FIGURE 5, looking in the direction indicated by the arrows s s in FIGURE 5;

FIGURE 7 is a side elevation of a further embodiment of the invention showing a dilterent mounting and releasing arrangement for the pedal-operated parking brake, the release mechanism being manually operated;

FIGURE 8 is a top view of the operating mechanism shown in FIGURE 7, looking in the direction indicated by arrows FIGURE 7;

FIGURE 9 is a side elevation of the final embodiment of the invention shown without a mounting bracket;

I-LGURE 10 is a sectional view of a final embodiment of the invention taken on line lit-1t of FIGURE 9;

FIGURE ll is a top view of the operating mechanism shown in FZGURE 10, looking in the direction indicated by the arrows ll-lit in FIGURE 10;

FIGURE 12 is a side elevation of the mounting bracket for the operating mechanism shown in FIGURES 91l;

FiGURE 13 is an end view of the mounting bracket shown in FIGURE 12, looking in the direction indicated by the arrows 13-13 in FIGURE 12;

FIGURE 14 is a sectional view, taken on the line 14- s eaves w 14 of FIGURE 12, showing the tabs formed for securing one free end of the clutch spring to the bracket;

FIGURE 15 is a side elevation of the complete assembly of the operating mechanism and mounting bracket shown separately in the previous figures;

FIGURE 16 is a sectional view, taken on line 16 in of EiGURE 15, showing the method of securing one free end of the clutch spring to the mounting brackets;

FIGURES l7 and 18 are outlines of the two flat stampings which make up the operating mechanism prior to any drawing or forming operations; and

FIGURE 19 is a graph showing actual experimental data of the brake release characteristics of the invention.

Referring now to FIGURES l and 2, the applying mechanism, designated generally by reference numeral ltl, comprises a depending lever or pedal 12 having a pad lit at one remote end thereof against which the operator applies his foot to actuate the parking brake. A cylindrical drum to is welded or otherwise secured to an enlarged end 18 of the pedal 12. The cylindrical drum in is flanged at 20 and welded around its periphery to the enlarged end 18 so as to be securely connected thereto. Thus, when the pedal R2 is caused to pivot, the drum 16 will turn therewith. The drum to and pedal 12 pivot on a stud 22 which is passed through both the pedal and the center of the drum. The end 2% of the stud 22 is reduced in diameter and threaded to assist in mounting the entire structure of the applying mechanism.

A mounting bracket 26 has spaced apart sides 28 and 3% which, in conjunction with the joining side 32, form a. U-shaped construction. The side 331 extends on the opposite side of the drum to form additional support for the stud 122. The stud 22 is thus journalled at its ends on sides 28 and 39 of the mounting bracket. An opening 34 is also provided in side 28 and a fastener passed through the opening The threaded end 2 of the stud 22. and the fastener {not shown) received through the opening 34 are received in a side wall (not shown), which forms part of the interior compartment of the vehicle.

The enlarged end of the pedal 12 (FIGURE 2) has an integrally formed projecting lug 36 Which is apertured at 38 for connection with an applying cable which leads to the brakes.

A portion (FIGURE 1) of the side 3b is struck from the side 3% and bent transversely to form a seat tor a rubber stop 42 which is designed to limit rotation of the lever 12 in a brake release direction. A projecting nib (not shown) is formed integrally with the enlarged portion 13 of the lever 12; this nib moves into contact with the stop 42 to prevent further rotation of the lever 12.

Surrounding the outer periphery of the drum 16 is a circular cross-section coil spring or other coiled flexible member 44- Whose inner diameter is less than the outer diameter of the cylindrical portion of the drum 16, thus providing an interference fit between the two parts. The spring 54 consists of a number or" coils which are arranged closely together with respect to each other and which are expanded over the drum. In so doing, the spring exerts a resilient gripping force on the cylindrical surface of the drum. The one end as of the spring is Wrapped around an anchor bolt which is received in side 28, the end as being thus fixed and nonmovable with respect to the drum &6.

Thus, when effort is applied to the pedal 12, the spring 44 will uncoil and allow the drum to be turned in that direction. When the tension in the applying cable con nected at 38 attempts to turn the pedal 12 and drum 15 in the opposite direction, the spring will coil tighter, increasing its frictional grip on the drum and prohibit the drum from turning in that direction.

A ridge St} is drawn in the side This ridge is generally circular and has a depressed circular recess 51 in its center that surrounds that portion of the spring end 46 which is bent around the anchor 43. This ridge and recess serve to hold the spring end as with respect to the side 28. The ridge 5% is not formed completely around the anchor 48 thereby allowing a portion of the sp 'ng to lie flat against the side The end of the spring 44 which is hooked over the anchor is held against the side 23 by means of an enlarged end 52 of the bolt and a washer.

The coil spring 4 terminates at the other end in a straight portion 54- which projects tangentially from the drum to and has an eyelet 56 formed in the end thereof. A manually operated lever mechanism (not shown) is error god to exert effort on the straightened end .74 to bend it downwardly, thus expanding the adjacent coils of the spring and relieving a part of the frictional gripping force between the coils and the drum hi to permit the cable, which is secured to opening 38, to swing the edal T2 in a brake releasing direction. The return of the pedal 12 is limited by re-engagement of the ntegral nib with the stop The release mechanism UL ized to expand the coils of the spring may be constructed so as to maintain constant expansion of the spring which permits the brake to be released alter actuation merely by the operator removing his foot from the peda. Thus, the described applying mechanism can be adapted to allow the drum to be turned in either direction.

As described, the bracket can be mounted on the side Wall of the drivers compartment, the pad 14 of the pedal 12 normally being contacted by the left foot of the vehicle operator. The pedal and applying mechanism are suspended sufilciently to the side and suhiciently high so as not to interfere with the other vehicle operating members. The mounting portion of the bracket 0 ists of the threaded end 24 of the pivot stud 22, the fastener member received through opening 3 3, and the threaded end of anchor 43. This three-bolt-mounting for the bracket is sufficient to hold the operating mechanism against any of the shear stress developed during brake application.

Referring next to the embodiment ltla shown in FIGURES 3 and 4, parts corresponding to those previously described will receive the same reference numeral, but include further the subscript a to distinguish the part from the previous embodiment.

A pedal 12a having a foot pad 144: is mounted for pivotal movement on a pivot bolt 22a which is supported at opposite ends on a fixed bracket 26a. The output end 36:: of the applying lever has fastened thereto a brake applying cable 57 passing through a conduit 58 which is secured to the fire-wall so of the vehicle. The cable 57 leads to the parking brake mechanism and a pulling effort exerted by the output end on the cable 5'7 is ultimately transmitted as actuating effort on the brake.

Referring to FIGURE 4, a drum loo having a flanged portion 20a is welded or otherwise secured in some suitable manner around its periphery to the portion of the pedal 12a. Thus, when the pedal 251 is caused to pivot the drum 16a is caused to turn therewith. The position of the applying mechanism in FTGURE 3 1s a normally released position. The portion 36a of the applying lever is in engagement with stop 42a, the stop 42a being secured to part of the mounting bracket 26a.

To lock the applying pedal in its various angular positions, there is provided a coil spring or other coiled flexible member designated generally by reference numeral 440. The one end 4512 is turned back and received through an opening in a transverse portion er. of the bracket which joins the spaced apart sides and Slia or" the bracket.

A number of coils of the spring are formed about the outer cylindrical surface of the drum lea just as in the previous embodiment. The inner diameter of the spring is less than the outer diameter of the drum 3.6a so that as the coils are forcibly expanded or sprung over the drum 16a they will exert a gripping action on the drum The coil spring terminates at the other in a str transverse portion 54:: which is secured to a fioati link The link is joined through a pivot pin to release lever 5d. The release lever 6% is fulcrumed at to the spea /es applying pedal 12a. At the end of the release pedal 68 is a pad 72 which is pushed on by the toe of the operator to release the locking portion of the applying apparatus and permit brake release.

in operation, the operator pushes with his foot on pad 14:: swinging the pedal 120 about its pivot and turning therewith the drum ltia. The turning of the lever about its pivot point develops a pulling force on the cable 57 to apply the brake. Thus, the degree of brake applying force is determined by the amount of turning of the lever and drum lea. When the applying effort on the pad lhia is relieved, turning of the pedal 12a in a brake release direction is prevented by the gripping action of the spring 4451, which serves as a one-way clutch preventing brake release. it thus happens that the applying apparatus is locked in a brake applying position, and this position can vary to any extent desired to give any degree of braking effort. With the applying apparatus thus held in a locked position, the brakes are applied and the vehicle is retarded against motion or, in the case of an emergency brake application, the brakes develop a retarding eilort tending to slow the vehicle wheels and stop their rotation.

To release the applying mechanism, the operator needs only to push on the pad 72, thereby pivoting the release lever 65 on the fulcrum 7d, and causing the floating link 64 to push outwardly on the end 54a of the spring which expands adjacent the coils of the spring and releases the frictional gripping force of the coils on the drum 16a. When the clutch spring does release its force on the drum 16a, the tension force on the applying cable 57 will swing the applying lever 12a until 36a is again brought into engagement with the stop 42:: thereby relieving applying force on the brakes.

Referring next to the embodiment shown in FEGURES 5 and 6, parts corresponding to those previously described will receive the same reference numerals, but include the subscript b.

There is included in this embodiment 1912 an applying pedal 125 which is pivoted at 22b and has a portion 36b adapted for connection with an applying cable (not shown). A drum 16b having a cylindrical surface is secured to the pedal 12b and is turnable therewith when effort is applied to the pedal 1% to acuate the brake. A one-way clutch consisting of a coil spring 4412 is used to lock the pedal 13) in any desired angular position, this angular position determining the amount of brake applying force communicated to the brake. When it is desired to release the brake, the operator merely pulls on handle 74, which is located on the dash 75. A rod 76 connects the handle I and the free end 54b of the spring 44b. The end S ib is thus pulled away from the drum expandthe adj cent coils of the clutch spring and relaxing the frictional grip of the spring 44]) on the drum i611. This permits the pedal 32/) to be returned to its original position wherein a portion of the pedal 12b contacts a fixed stop, just as in previous embodiments. The applying mecha nism is mounted on the firewall 77, as shown.

In this embodiment the brake is pedal-operated and locked and thereafter manually released by pulling on the handle 7 Referring next to the embodiment the shown in FIG- RES 7 and 8, wherein the reference numerals will include the subscript c to distinguish them from parts previously described, there will be shown a method in which manual release occurs by pushing down on a manually operated lever.

The pedal 120 is fulcrumed at a portion between its ends on pivot pin 22c. Applying effort is exerted against the pad 14C to swing the pedal downwardly, and develop pulling force on the applying cable which leads to the brake. A one-way clutch spring 440 grips cylindrical drum 16c which is fixed to the pedal the same as in the previous embodiments. i /hen it is desired to release the brake, the handle 74a is pushed downwardly as indicated by the dotted arrow in FXGURE 7. The free end 540 of X.) the spring is pushed downwardly thereby expanding the adiacent coils of the clutch spring 440. When the coil spring is thus expanded, its frictional grip on the drum lee is relaxed sufficiently to permit the applying cable to return the pedal to its original position wherein it contacts a fixed stop just as in the previous embodiments.

There is some advantage to this release technique since the handle 74c instead of being drawn outwardly can merely be swung downward. Considerable force can be developed in this manner. Mounting bracket, designated generally by reference numeral 260, has a number of holes indicated at 73 which can receive fasteners (not shown) to connect the bracket 26s with a portion of the vehicle in the interior compartment on the firewall or side kick panel, etc.

Referring next to the embodiment ifid shown in Fl- URES 9, 10 and ll, portions of he actuating system corresponding to those previously described will be referred to with the same reference numeral but include also the subscript zl to distinguish them from previous components.

in FIGURES 9, l0 and ll, there are shown detail views of the applying lever components without the mounting bracket. The parking brake mechanism is made up of two stampings and 82. The stamping 8t: is formed initially as a flat member and has at the one end a bentover pedal half ti t and a transverse strengthening rib portion 86. Centrally of the stamping is a drawn cylindrical portion 88 having an opening 98. The drawn portion 83 has a cylindrical drum section @2 which is combined with the spring clutch member 94. A portion 96 of the drawn section 83 lies fiat gainst stamping 82 and is welded at 93 to the stamped portion 32 so that the two portions together make up the pedal and drum assembly. The stamping 82 has a transverse pedal portion which is in ali nment with pedal portion of the stamping 3 to make up the complete pedal pad 14d. Likewise, a strengthening web is formed symmetrically with portion 86 to provide additional transverse strengthening.

At the opposite end iii-t of the pedal 14a, the two stamping portions lie flatly together and an opening N36 is pro vided th rein for attachment with an applying cable. The spring 94 in contrast with the previously described springs, is rectangular in cross section and lies flatly against the drum surface to provide maximum gripping surface along the entire lateral width of the drum. Because of the added gripping surface of the flat wire, a narrower drum surface is required to provide locking action on he pedal.

FZGURES l2 and 13 are front and side views respectively of the mounting bracket. The mounting consists generally of a il-s'naped bracket which serves to pivotally suspend the actuating pedal ills. The bracket consists of two spaced sides 1% and lit! which are joined by portion 112. The bracket is fastened to the side kickboard in the drivers compartment by means of fasteners (not shown). These ta eners are received through opening lid in the side 1%. Openings M5 in sides 1% and 119 are to receive the stud upon which the pedal assembly pivots. An opening 116 is provided in side 1312 for the applying cable which is threaded through the opening for attachment with opening 1% in the applying pedal 12d. Side 11G has a tab 118 which is formed integrally therewith, this tab being struck from the side lit} and bent over so as to provide a seat for a stop 132 which limits movement of the applying pedal in a brake release direction.

The side 198 is adapted for securement with the spring 94. Referring to FIGURES l2, l4 and 15 at the upper edge 120 of the side 103 there is a sheared portion which permits a tab to be bent away from the side. Also in side 1% is a struck otiset finger 1Z4.

Referring next to FIGURES l0, l5 and 16, there will e described the final assembled brake pedal and bracket. In FIGURE 10, the spring M- is stretched over drum section 92 of the stamping iii, and thereafter the stamping 82 is welded to the stamping iii to $8 to hold the two stampspea /es The two stampings thus enclose the spring The two joined stampings, along with the spring, are now ready for attachment with the bracket. Referring to FIGURES l and 16, as the pedal is fitted between the sides of the bracket, the looped end 126 of the spring is caused to slide between the tab 122 and the side Hi3, and the end of the loop 126 passes between the finger 12d and the side 1 38. Thereafter, the pedal is held in place by means of a pivot pin 12.8 which passes through openings 9 3 in sides 86* and 32 and the openings 115 in sides 108 and 119 of the mounting bracket.

The end 126 of the spring is held permanently in place by swaging the tab 122 back to its original shape. Referring to FIGURE 15, the portion 1% of the tab is brought back into conformance with the side 1438 of the bracket and the portion 122 (FIGURE 16) lying adjacent the spring becomes enlarged and bulbs out to lock the end and hold it in place. The linger 124 is then crimped tightly against the end 126 to provide further locking action on the end of the spring.

To apply the brake, the pedal pad 14d which is made up of portions 84 and 1% is depressed (referring to FIG- URE 15), thus rotating the applying lever clockwise on pivot 12-3. Whatever angular position the pedal 100 is moved to by the operators effort, the pedal will be held in locked position after the applying effort is released by means of the clutch spring 94. When it is desired to release the brakes, manual or pedal effort can be used for pulling the end kid of the spring away from the drum 92. When the end 134 is pulled away, the coils of the spring are expanded and this releases their gripping effort on the drum and permits the tension in the applying cable to rotate the pedal counterclockwise (FIGURE 15) until the pedal engages with a resilient stop 13-2 which is fitted into tab 113.

One of the main advantages of this last described embodiment is the ease with which it can be manufactured. The whole brake assembly consists essentially of a pedal, spring and a bracket. The portions which make up the pedal and the drum are formed from only two stampings and the method of manufacture can be continuous and is easily adapted for large scale manufacture. Referring to FIGURES 17 and 18, there is shown the outline of parts Eli and 82, respectively, in a flattened condition and prior to the various drawing and bending operations which subsequently take place to complete the final article. The outline shown in FlGURES 17 and 18 are formed gradually out of a sheet of continuously travelling sheet-metal stock. The various cutting operations are performed at successive stations and gradually so that the piece is carried along with the stock until it is finally stamped out at the end of the operation.

It can be seen which of the portions of the stamping become formed into the parts indicated in FIGURE 10. For example, the region 136 is bent over to become portion 34- of the pedal. The portion 138 becomes the transverse strengthening rib as, and at the region 149- there is a series of drawing steps in which the draw becomes successively deeper and sharper edged until it eventually assumes the shape indicated in FIGURE 10, in which there is a drum portion 92 which provides spacing so that the two pedal halves are journalled at spaced points on the pivot pin 1.28.

The segment 142 is folded over so that it becomes the portion of the lever which contacts the resilient stop 132 that is mounted in tab 118 of the bracket.

Referring next to FEGURE 18, it will be seen that the stamping shown, which makes up side 82, is approximately symmetrical to the stamping which makes up side 84). The stamping which makes up the side 82, was approximately the same in general outline as the other stamping but is somewhat smaller since this is not the portion which makes up the drum. Zone 144 is bent over to complete the pedal portion. Zone 146 is bent over to form the strengthening ribs. In the circular zone 14%, there is a slight draw which is formed to complete the cavity creatings together.

ed between the two sides when they are fastened together. The slight recess is partially flattened to ensure contact with portion 96 of the other stamping to enable a better series of welds 98 to be made and a resulting better connection. The opening 1% is formed in the stamping to adapt the applying pedal for attachment with the apply ing cable.

The portion 82 can also be made from continuously travelling sheet-metal stock so that the manufacture of the complete pedal is not only a very simple and efficient method of manufacture, but it is adapted for large scale manufacture and can thus be made very economically.

There is shown in FIGURE 19 an operational advantage of all of the embodiments described. This advantage can be stated in terms of the release load v. cable load. By cable load is meant the amount of applying force which is developed on the applying pedal and communicated to the brakes as applying effort thereon. The release load is a measure of the amount of effort that needs to be developed to release the brake. It is characteristic of the invention that with a given brake, pedal and clutch-spring design, that the release load remains constant regardless of the amount of applying effort which is applied to the brakes. Referring to FIGURE 19, which is a graph showing actual experimental evidence of the brake release characteristics, it will be seen that the release load does not vary appreciably regardless of the cable load. This means that, regardless of the applying effort which is exerted on the brakes by the applying pedal in its locked position, there will be no change in the releasing effort necessary to unlock the applying pedal and allow it to return to its original position thereby relieving the brake applying load. Vve regard this as a substantial advantage in that most people are capable of developing considerably more force with their foot in applying the foot-operated parking brake than they are in releasing the brake by a manual pulling or pushing operation, and that, from past experience, it is quite possible for the Vehicle driver to apply the brake with such force that it is impossible or very difiicult to release the brake with the releasing means provided.

The different lines which are shown in FIGURE 19 indicate six different release loads which can be provided depending upon the gripping force between the coil spring and the drum, this being obtained by selecting the relative diametral dimension of the spring and drum, respectively. Where the inner diameter of the spring coil is very much smaller than the drum, then the gripping action of the spring is greater and develops higher orders of releasing loads, but these loads do remain constant irrespective of the applying force which determined the angular position of the pedal in its locked position. Likewise, although the different release load is possible as indicated with the other five, this release load does remain constant.

Although there are only a few selected example embodiments of the invention which have been chosen to describe the invention and its method of manufacture, it will be appreciated that these are merely illustrative of the invention and are not to be interpreted as restrictive thereof.

It is intended that such revisions and variations of the invention as are reasonably expected on the part of those skilled in the art will be included within the scope of the following claims.

We claim:

1. A method for manufacturing a brake applying apparatus comprising the steps of blanking two pedal halves from sheet-metal stock, drawing a cylindrically shaped boss from one of said pedal halves which forms a drum surface, bending over two pad portions which are integral with said pedal halves, expanding a coil spring over said drum surface to be in gripping engagement therewith, and joining said pedal halves to confine the spring therebetween.

2. The process of claim 1 including the step of bending over a portion of said pedal along the length thereof to form a strengthening web.

3. The process of claim 2 including the steps of providing a supporting bracket, shearing and bending back a portion of said bracket, lancing and bending back a finger in said support oppositely to said sheared portion, passing a looped end of said spring between said sheared and lanced portions, and crimping said sheared and lanced portions against said loop to tightly secure the end of said spring to the bracket.

4. The process of claim 3 including the steps of fitting References Cited in the file of this patent UNITED STATES PATENTS Hallowell June 22, 1909 Wenn Apr. 30, 1940 McCarthy et a1 Sept. 22, 1959 

